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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1720 (Engine - 2.3L) >> In-Vehicle Repair >> Cylinder Head >> Removal

Cylinder Head: Removal

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  3. Check the valve clearance. For additional information, refer to VALVE CLEARANCE CHECK .
  4. Remove the degas bottle. For additional information, refer to ENGINE COOLING .
  5. Remove the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
  6. Remove the generator. For additional information, refer to GENERATOR AND REGULATOR .
  7. Remove the fuel supply rail. For additional information, refer to FUEL CHARGING & CONTROLS - 2.3L .
  8. Remove the intake manifold. For additional information, refer to INTAKE MANIFOLD .

    9. Vehicles with secondary air injection (AIR) 

  9. Disconnect the secondary air injection (AIR) pump electrical connector.
  10. Remove the 3 bolts and position the AIR pump aside.

    11. All vehicles 

  11. Remove the bolt and the radio frequency interference capacitor from the engine mount bracket.
  12. Remove the engine mount bracket bolt.
  13. Install the special tool and a suitable length of chain to the threaded hole in the LH side of the engine block.
    Fig 1: Identifying Special Tool
    G04680096Courtesy of FORD MOTOR CO.
  14. Install the special.
    • Using the special tool, lift the engine 25 mm (0.98 in).
      Fig 2: Identifying Special Tool
      G04680097Courtesy of FORD MOTOR CO.
  15. Remove the nut, 2 bolts and the engine mount.
  16. Lower the engine 25 mm (0.98 in).
  17. Remove the 2 nuts and the engine mount bracket.
  18. Remove the timing drive components. For additional information, refer to TIMING DRIVE COMPONENTS .
  19. Remove the special tool.
    Fig 3: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  20. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
    Fig 4: Locating Camshaft Lobe
    G03898791Courtesy of FORD MOTOR CO.
  21. Remove the bolt and the variable camshaft timing (VCT) solenoid.
    22. CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
  22. Remove the camshafts from the engine.
    • Loosen the camshaft bearing cap bolts, in the sequence shown, one turn at a time until all tension is released from the camshaft bearing caps.
    • Remove the bolts and the camshaft bearing caps.
    • Remove the camshafts.
      Fig 5: Identifying Loosening Sequence Of Camshaft Bearing Cap Bolts
      G04680100Courtesy of FORD MOTOR CO.
    23. CAUTION: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.
    NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
  23. Remove and inspect the valve tappets. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  24. Detach the retaining clip and position the evaporative emissions (EVAP) tube bundle aside.
    Fig 6: Locating Retaining Clip
    G04680101Courtesy of FORD MOTOR CO.
  25. Disconnect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose from the engine coolant outlet.
  26. Disconnect the engine coolant temperature sensor (ECT) electrical connector.
  27. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
  28. Disconnect the coolant hose from the EGR valve.

    29. Vehicles with secondary air injection (AIR) 

  29. Remove the 2 bolts and position AIR valve bracket aside.

    30. All vehicles 

  30. Remove the 10 bolts and the cylinder head.
    • Discard the bolts.
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